Pile diaper



Feb. 6, 1968 s. c. SCHEIER 3,357,333

PILE DIAPER Filed July 12, 1965 5 Sheets-Sheet 1 ATTORNEYS Feb. 6, 1968s. c. SCHEIER 3,367,333

FILE DIAPER Filed July 12, 1965 5 Sheets-Sheet 2 INVENTORZ 1 STANLEY C.scH

ATTORNEYS Feb. 6, 1968 s. c. SCHEIER 3,

FILE DIAPER Filed July 12, 1965 5 Sheets-Sheet 5 5TAN LEV C. ScH E\EE.

INVENTOR I ATTQRNEY-S Feb. 6, 1968 s. c. SCHEIER 3,367,333

FILE DIAPER Filed July 12, 1965 5 Sheets-Sheet 4 ATTORNEYS Feb. 6, 1968s. c. SCHEIER 3,367,333

FILE DIAPER Filed July 12, 1965 5 Sheets-Sheet 5 STANLEY C. Scj gATTORNEY$ United States Patent 3,367,333 FILE DIAPER Stanley C. Scheier,Charlotte, N.., assignor to The Kendall Company, Boston, Mass, acorporation of Massachusetts Filed July 12, 1965, Ser. No. 471,216 '19Claims. (Cl. 128-234) The present invention relates to diapers and moreparticularly to improved diapers having at least one pile portion orarea and other portions or areas devoid of pile, which portions areconstructed and arranged to provide highly desirable diapercharacteristics or features, such as increased absorbency, softness,and/or wearer comfort, not heretofore provided by conventional diapers.

It is well known that absorbency, softness, wearer comfort and the likeare highly desirable characteristics or features for a diaper. Also, itis well recognized that greater absorbency is needed in a centralportion of a diaper than in the remaining portions thereof. With this inmind, it is common practice to fold conventional diapers in such amanner that a greater number of fabric layers are provided in thecentral portion than in other portions to provide the desired absorbencytherein. This practice is particulorly prevalent with diapers of theprefold type which are folded to a size adapted to fit an infant andstitched in folded condition by the diaper manufacturer. While providingthe desired greater absorbency, the greater number of fabric layers inthe central portion of there diapers create certain problems in use,such as increased bulkiness between the infants legs.

Various other constructions have been proposed to provide the greaterabsorbency in the central portion of the diaper. One such approach hasproposed the provision of either permanently attached or removablediaper liners or pads. These liner or pad constructions suffer from theaforementioned problems to an even greater extent than conventionaldiapers and, in addition, are expensive to manufacture and bothersome touse.

It ha also been proposed that a diaper could be constructed of woventerry fabric in an attempt to provide the desired absorbency in thecentral portion of the diaper while obviating the problems encounteredwith the conventional diaper as described above. However, such woventerry fabrics are formed by a special weaving process wherein both aground Warp and a pile warp are utilized and the pile yarns are woven asan integral part of the ground fabric. Therefore, the ground or basemust be a woven fabric of interwoven warp and filling yarns and otherpossibly desired ground or base materials may not be used. Also, thepile arns must have suficient twist therein to withstand the stressesthereon during weaving of such yarns in the fabric and this relativelyhigh twist results in increased harshness and reduced absorbency in thepile surface. Thus, terry fabrics cannot provide the desired softnessand absorbency in a diaper. For these reasons as well as other reasonsincident to the nature of the special weaving process required toproduce terry fabric, pile diapers of terry fabric have not beencommercially accepted in this country.

Further, the discomfort of the wearer due to the lingering presence of amoisture laden or wet surface in contact with the wearers skin has givenrise to various diaper constructions which attempt to provide increasedwearer comfort by utilizing a hydrophobic portion adapted to contact thewearers skin to wick the moisture therefrom and a hydrophilic portiondisposed away from the wearers skin to absorb the moisture being wickedaway by the hydrophobic portion. Since the hydrophobic portion does notabsorb the moisture, a drier surface is provided against the wearersskin which enhances the comfort of the wearer and inhibits the formationof certain skin maladies, such as diaper rash.

"ice

With previous constructions of this type, it is common practice toutilize special weaves to provide woven fabrics having hydrophobic yarnspredominately on one surface and hydrophilic yarns predominately on theother surface thereof. With such previous diapers, it has not beenpossible to obtain the desired absorbency in the diaper and this isparticularly true with respect to the central portion of the diaper.

It is, therefore, an object of the present invention to provide a pilediaper obviating the aforementioned problems and deficiencies ofconventional diapers and previously proposed pile diapers by providingthe desired softness and absorbency without relying upon folding toprovide an increased number of layers in the central portion, inserts orpads, or special weaves.

A more specific object of this invention is to provide a pile diaperwherein the base and/or pile yarns may be formed of a wide variety ofmaterials for achieving diaper characteristics, such as a high degree ofabsorbency, softness and wearer comfort, not heretofore achievable indiapers.

A further more specific object of the present invention is to provide apile diaper wherein the pile is anchored in ,the base without beinginterwoven therewith to preventany weakening of the base upon any damageto the pile.

A still more specific object of this invention is to provide a pilediaper wherein pile yarns may be utilized of such low twist as to beimpractical for use in woven pile fabrics, such as terry fabrics, butvery desirable for use in diapers due to the increased softness and/orabsorbency thereof.

Another object of the present invention is to provide a pile diaperhaving hydrophobic and hydrophilic characteristics for increased wearercomfort without relying upon special weaves, and wherein the desiredabsorbency, particularly in the central portion of the diaper, isprovided.

Some of the objects of the invention having been stated, other objectswill appear as the description proceeds when taken in connection withthe accompanying drawings in which:

FIGURE 1 is a generally schematic view illustrating the manner offorming a web of diaper material in accordance with the presentinvention from which finished diapers may be formed;

FIGURE 2 is an enlarged fragmentary sectional view taken substantiallyalong line 22 in FIGURE 1;

FIGURE 3 is an isometric view of a finished diaper incorporating thefeatures of the present;

FIGURE 4 is a partially schematic, enlarged fragmentary perspective viewof the portion of diaper enclosed in the rectangle 4 in FIGURE 3;

FIGURE 5 is a transverse sectional view of a modified form of diaperembodying the features of the present invention;

FIGURE 6 is an enlarged fragmentary plan view of the central portion ofthe diaper shown in FIGURE 5;

FIGURE 7 is a bottom plan view of the central portion of the diapershown in FIGURE 5;

FIGURE 8 is a view similar to FIGURE 4 illustrating still another formof diaper constructed in accordance with the present invention;

FIGURE 9 is a reduced end elevational view looking in the direction ofthe arrow 9 in FIGURE 8;

FIGURE 10 is a fragmentary view of a section of corespun yarn adapted tobe used in another form of diaper constructed in accordance with thepresent invention;

FIGURE 11 is an isometric view of a modified form of diaper of thepresent invention having a pile face on opposite outer surfaces thereof,and illustrating the manner of folding thereof;

FIGURE 12 is an isometric view of a finished form of the diaper shown inFIGURE 11 with a portion broken away to illustrate the folded edge;

FIGURE 13 is an enlarged transverse sectional view taken substantiallyalong the line 1313 in FIGURE 12;

FIGURE 14 is an isometric view similar to FIGURE 11 of another form ofdiaper having pile faces on opposite surfaces thereof and illustratingthe manner of folding thereof;

FIGURE 15 is a view similar to FIGURE 12 and illustrating a finishedform of the diaper shown in FIGURE 14 with a portion broken away toillustrate the folded edge thereof;

FIGURE 16 is a fragmentary isometric view of the central pile portion ofa diaper formed in accordance with the present invention;

FIGURE 17 is an isometric view similar to FIGURE 16 of a diaperconstructed in accordance with the present invention wherein the pileyarns are formed of hydrophilic material and are shown after repeatedlaunderings;

FIGURE 18 is an isometric view of the reverse side of the portion ofdiaper shown in FIGURE 16;

FIGURE 19 is an isometric view of the reverse side of the portion ofdiaper illustrated in FIGURE 17;

FIGURE 20 is a view similar to FIGURE 19 of a portion of diaper whereinboth hydrophobic and hydrophilic yarns have been utilized and showingthe effects of repeated launderings upon those two types of yarns;

FIGURE 21 is an isometric view of the reverse side of the fabric shownin FIGURE 20;

FIGURE 22 is an enlarged end elevational view of the diaper shown inFIGURE 21 looking in the direction of arrow 22 therein;

FIGURE 23 is a plan view of a diaper blank adapted to be formed into afurther modified form of diaper in accordance with the presentinvention;

FIGURE 24 is an enlarged transverse sectional view of the finisheddiaper formed from the diaper blank shown in FIGURE 23;

FIGURE 25 is a plan view similar to FIGURE 23 of another diaper blankadapted to be formed into another modified form of diaper embodying thefeatures of the present invention;

FIGURE 26 is an enlarged transverse sectional view of the finisheddiaper formed from the diaper blank shown in FIGURE 25;

FIGURE 27 is a plan view similar to FIGURES 23 and 25 of still anotherdiaper blank adapted to be formed into a still further form of diaper inaccordance with this invention; and

FIGURE 28 is an enlarged transverse sectional view of the finisheddiaper formed from the diaper blank shown in FIGURE 27.

Generally, the present invention contemplates several forms orembodiments of diapers which are characterized by at least one pileportion or area and other portions or areas devoid of pile, whichdiapers are constructed and arranged to provide highly desirable diaperfeatures or characteristics, such as increased absorbency, softness,and/ or wearer comfort, not heretofore provided by conventional diapers.The diapers of the present invention are preferably formed by firstforming a web of diaper material D (FIGURE 1) which is then transverselysevered into diaper blanks. The diaper blanks are then formed into thefinished diapers, such as diaper 30 (FIG. URE 3), as will be describedmore fully hereinafter.

In the embodiments illustrated in the drawings, the web of diapermaterial D (FIGURE 1) is preferably formed on a machine of the typeillustrated in United States Patent No. 3,174,308. The web of diapermaterial D includes a base web B, which extends throughout the web ofdiaper material D, and a severed length of which forms the base of adiaper of the present invention, such as base 31 of diaper 30. Pileyarns, such as pile yarns 32 of diaper 30, penetrate through and areanchored within at least one portion of the base web B and form pile,such as pile loops 33 of diaper 30, on one surface thereof and areinterknit and form stitch loop chains such as stitch loops 34 of diaper30, on the other surface thereof. The pile yarns and the at least oneportion of the base through which they penetrate cooperate to define atleast one pile area in the web of diaper material D which will define apile area, such as pile area 35 of diaper 30, in the finished diaper.

The machine for forming the web of diaper material D by combining thepile yarns with the base web includes a bank of needles N (FIGURE 2),which are of a combined width corresponding to the desired width of thepile area in the web of diaper material and are reciprocated tosuccessively penetrate and be withdrawn from the base web. Needles N areassociated with suitable yarn guides G, with a yarn guide being providedfor each needle and having a pile yarn threaded therethrough. Pile wiresP are disposed between adjacent pairs of needles N and extend generallyperpendicular thereto and parallel to the path of travel of the base webas the same is fed past the needles.

Yarn guides G are reciprocated laterally of the base web betweenadjacent pairs of needles in timed relation to the reciprocation of theneedles to move each pile yarn 32, except for the distal yarns 32 in thebank of pile yarns, into position to be caught by the hook portion offirst one needle and then the hook portion of another needle in theadjacent pairs of needles so that a pile yarn will be drawn through thebase web by first one needle and then another needle at both laterallyand longitudinally spaced points upon each reciprocation of the needles.The reciprocation of the yarn guides G between adjacent pairs of needlesalso results in the pile yarns being shogged back and forth over thepile wires P so that when the needles are withdrawn from the base Web,the pile wires hold portions of the pile yarns away from the surface ofthe web and form the pile which may be either cut or uncut as desired.Of course, the height of the pile may be varied by varying the height ofthe pile wires P. The portions of the pile yarns which are drawn throughthe base web upon each withdrawal of the needles N, are held on theneedles for one complete reciprocation thereof so that these portionsare interknit and form stitch loop chains on the reverse side of thebase web from the pile portions.

It is contemplated by the present invention that the base web B may beformed of any pliable material, with the particular material useddepending upon the characteristics desired in the finished diaper. Someexamples of materials suitable for use as the base web are a pre-wovenfabric, a pre-formed non-woven fabric, and a pre-knitted fabric.Further, a fabric of the type illustrated in United States Patent No.2,890,579 may be utilized as the base web if desired, and in such anevent, the machine fOUIl'.

ing this fabric may be arranged in tandem with the machine forming theweb of diaper material. The base web may then be fed directly from onemachine into the other machine.

Similary to the base web B, the pile yarns may also be of any desiredmaterial depending upon the characteristics desired in the pile area ofthe finished diaper. In this respect, if softness and absorbency are thecharacteristics desired in the pile area of the finished diaper, thepile yarns should be formed of a hydrophilic material and preferably areformed of Water swellable cellulosic material, such as staple viscoserayon. Also, these pile yarns preferably have a size within the range ofabout 3/1 and 25/1 (cotton count) to provide the degree of absorbencydesired and for more complete coverage of the surface of the base web.Due to the special structural character of the pile area of the web ofdiaper material D, these pile yarns may also have such low twist thereinas to make such yarns impractical for use in woven fabrics, such asconventional diaper fabrics or terry fabrics, but which greatly enhancesboth the softness and absorbency of the pile area of the finisheddiaper. In this respect, the pile yarns for the diapers of thisinvention preferably have a twist multiple (turne per inch divided bythe square root of the yarn size) of no more than 3.5 which is below thestandard twist multiples for diaper fabrics.

Turning now to a consideration of the illustrated forms or embodimentsof this invention, diaper 30 (FIGURE 3) includes elongate base 31 whichpreferably is of single layer construction and which may be of anydesired material, such as non-Woven fabric of either hydrophobic orhydrophilic fibers. Pile yarns 32 penetrate through a selected portionor area of base 31 and form pile loops 33 on one surface thereof andinterknit stitch loops 34 on the other surface to define a pile area 35,which preferably is in the central portion of the base and defines apile central panel extending between the ends of the diaper and having awidth substantially equal to one-half /2) the width of the diaper 30.Due to the manner of formation of pile loops 33 as described above, theyare arranged in parallel rows extending lengthwise of the base 31(FIGURE 4) and are disposed in a zig-zag pattern in each of the rows,with the points of penetration of the base 31 by the leg portions of thepile loops in one row and the proximal leg portions of the pile loops inthe adjacent row being aligned longitudinally of the rows and the base.

Base 31 has portions 36 and 37 on opposite sides of the pile centralpanel 35 which are devoid of pile and which define pinning panels in thefinished diaper 30. These pinning portions 36, 37 have outer side edges38 and 39, respectively, which are finished to prevent fraying orraveling by any suitable means. The cut ends of the diaper 30 which wereformed when the same was severed from the web of diaper material arealso finished by any suitable means, such as overedge stitching 40, 41.

As stated above, pile yarns 32 may be formed of either hydrophobic orhydrophilic material, but in diaper 30, these yarns preferably consistessentially of hydrophilic material for both softness and absorbency.More preferably, pile yarns 32 are formed of water swellable, cellulosicfibers, such as viscose rayon, which will shrink upon repeatedlaunderings. Due to the special construction of the pile central panel35 of diaper 30, and other diapers produced in accordance with thisinvention, very special and desirable characteristics are achieved aftersuch repeated launderings. These very desirable characteristics havebeen illustrated in FIGURES 16 through 19 wherein portions of diaper 30are shown both before any laundering thereof (FIGURES 16 and 18) andafter repeated launderings (FIGURES 17 and 19), e.g., fifteen suchlaunderings.

In this respect, as initially formed, the pile loops 33 are of a rathersubstantial, common height above the base 31 (FIGURE 16) and the stitchloop chains 34 are relatively tight and lie rather closely against thebase 31 (FIGURE 18). Upon such repeated launderings, the cellulosic pileyarns 32 swell and shrink due to the effects of the washing medium andmechanical agitation of the diaper, and the pile loops 33' are drawncloser to the surface of the base 31 and assume a more randomly orientedarrangement and, due at least in part to the yarn shrinkage and swellingand this random arrangement, form a closely matted surface on the base31'.

In addition, the twist in these yarns has a tendency to relax and theyarns open or blossom-out due to separation of the individual fiberstherein. Such opening or blossoming of the pile yarns materiallyenhances the absorbency and softness thereof and also increases thecoverage of the base 31 and contributes to the matted nature of thesurface defined by pile loops 33'. Further, if base 31 is formed ofcellulosic material, it will also shrink during such launderings andthis will result in the pile loops 33 being closer together and willprovide greater coverage of the base thereby.

At the same time that the pile loops 33' become shortened or reduced inheight, the stitch loops 34' become loosened to provide a more raisedsurface on this side of the base 31'. Also, the yarn portions definingthe stitch loops 34 open or blossom-out to provide a considerablysofter, more absorbent, and more compact surface on this side of base31. Accordingly, both surfaces of the diaper 30' have the absorbency,softness and compactness thereof considerably enhanced by thelaunderings to which diapers are invariably subjected.

Another form of diaper, generally indicated at 30a is shown in FIGURES 5through 7 and includes another type of base 31a which comprises apre-woven fabric, which may be of single or multi-layer construction,but preferably comprises upper and lower diaper layers 43 and 44, eachof which includes inter-woven sets of warp and filling yarns 45, 46,respectively (FIGURES 6 and 7). It is noted that the multi-layercharacter of base 31a permits the needles N to more readily penetratetherethrough than through a single layer base of denser construction andrupturing of warp and/or filling yarns in the fabric of the base isreduced or avoided.

IPile yarns 32a penetrate through the central portion of both of thelayers 43, 44 in the manner described above and form pile loops 33a onone surface thereof and stitch loops 34a are on the other surfacethereof. It is noted that the pile yarns 32a secure the central portionof the two layers together and cooperate therewith to define a pilecentral panel 35a. Since the leg portions at one side of adjacent pileloops 33a penetrate the base 31a at a common point (FIGURES 6 and 7) andeach of the pile loops extend diagonally of the base, all of the fillingyarns 46 extend beneath pile loops and there are no filling yarnsbetween adjacent loops in the rows, as in terry fabric. Also, since thepoints of penetration of proximal leg portions of the pile loops inadjacent rows are aligned, all of the warp yarns 4'5 extend beneath pileloops 33a and there are no warp yarns between the rows of pile loops asin terry fabric. Accordingly, more complete coverage of base 31a by pileloops 33a may be provided.

Portions of the layers 43, 44 on opposite sides of the pile centralpanel 35a are devoid of pile and remain independent of each other todefine pinning panels 36a, 37a. It is noted that the multi-layerconstruction of these pinning panels 36a, 37a and the independent natureof such layers facilitate the insertion of pins therethrough for ease inpinning the diaper on the wearer. The side edges 38a, 39a and ends (notshown) are secured together and finished, as by over-edge stitching toprevent raveling and/or fraying.

The fabric layers 43 and 44 may be woven in any desired weave design toprovide the desired strength, softness, and pliability in base 3111.Examples of weave designs which have been used in producing diapers inaccordance with this invention are a plain weave design, with a fabricconstruction in the range of conventional gauze diaper fabric, and abirdseye weave design, with fabric construction also within the range ofconventional birdseye diaper fabric.

A third form of diaper, generally indicated at 30b, is shown in FIGURES11 through 13 and differs from the above-described diapers 30 and 30aprimarily in that a pile face is provided on opposite outer surfacesthereof. Diaper 3011 includes an elongate base 31b preferably comprisinga single layer of pre-woven textile fabric having pile yarns 32bpenetrating through a medial portion thereof and forming pile loops 33bon one surface thereof and interknit stitch loops 34b on the othersurface thereof and defining therewith a pile central panel 35bextending between the ends of the base 31b.

Diaper 30b is formed by severing the web of diaper material defined bythe base web and the pile yarns at spaced points corresponding to twicethe desired length of the finished diaper. This severed length of diapermaterial or diaper blank is then folded about a medial transverse foldline to form superposed upper and lower diaper sections 50 and 51, eachof which have pile yarns 32b penetrating through the central portionthereof. The pile loops 3312 on each section are disposed on the outersurface thereof and the stitch loops 34b are disposed on the interiorsurface thereof so that the pile central panel 35b has a pile face onopposite outer surfaces thereof (FIG- URE 1-3).

Upper and lower sections and 51 are preferably secured in theirsuperposed relation as by overedge stitching 52 across the end thereofopposite the fold line and overedge stitching 53 and 54 along oppositeside edges thereof. The sections 50 and 51 are therefore independentthroughout except at the fold line and the end and side edges thereofwhich provides greater pliability and facilitates insertion of pinsthrough the side portions of the upper and lower sections 50 and 51 ofbase 3111 which define pinning panels 36b and 37]).

A fourth diaper form, generally indicated at 300, is shown in FIGURES 14and 15 and is similar to diaper 30b described above, differing therefrommainly in the manner of the folding of the diaper blank to form thefinished diaper. To produce this diaper, a base web having a width twicethe desired width of the finished diaper is provided, as are two banksof pile yarns 320. Two spaced apart banks of needles N are utilized withthese pile yarns to form two spaced apart pile areas or portionsextending longitudinally of the base Web. The thusly formed web ofdiaper material is then severed at spaced points corresponding to thedesired length of the finished diaper to form a diaper blank.

This diaper blank is folded about a longitudinal medial fold line toprovide superposed upper and lower sections 55, 56, each of which havepile yarns 32c penetrating through the medial portion thereof andforming pile loops 330 on one surface thereof and stitch loops 346 onthe other surface thereof. The pile loops 33c on each section aredisposed on the outer surface thereof and the stitch loops 340 aredisposed on the interior surface thereof so that pile central panel 350defined by these medial portions has a pile face on the opposite outersurfaces thereof Upper and lower sections 55 and 56 are preferablysecured in their superposed relation as by overedge stitching 57 alongthe side edge thereof opposite the folded edge and overedge stitching 60and 61 across opposite ends thereof.

The structural characteristics of the diapers of the present inventionrender the same especially well suited for the use of combinations ofhydrophobic and hydrophilic materials, which diapers not only possessthe desired absorbency characteristics but also provide increased wearercomfort. In this respect, at least the skincontacting surface of thediapers should be formed of the hydrophobic material so that the samewill wick moisture away from the wearers skin or remove this moisturefrom the wearers skin by capillary action. Other portions of the diapershould be formed of the hydrophilic material and should be arrangedrelative to the hydrophobic portion or portions so as to absorb themoisture being wicked away from the wearers skin by the hydrophobicportions and to retain this moisture away from the wearers skin toprovide the increased comfort for the wearer and to inhibit theformation of diaper rash.

Several forms of diapers utilizing this combination of materials areillustrated, the first of these being a diaper, generally indicated at30d, shown in FIGURES 8 and 9. This diaper 300. includes a base 31d,which may correspond generally to the base of any of the precedingdiapers, and pile yarns 32d penetrating through the base. Certain of thepile yarns 32d are formed of hydrophobic material, such as polypropyleneor nylon, and the other pile yarns 32d" are formed of hydrophilicmaterial, such as viscose rayon or cotton. Preferably, hydrophobic pileyarns 32d form pile loops 33d of a height greater than the height ofpile loops 33d" formed by hydrophilic pile yarns 32d. In the embodimentillustrated in the drawings, hydrophobic pile yarns 32d and hydrophilicpile yarns 32d" are arranged in alternation in the bank of pile yarnsand hydrophobic pile loops 33d form alternate rows of pile loops in pilecentral panel 35a" and hydrophilic pile loops 33d form intervening rowstherein or vice versa. Due to the interknitting of the stitch loopportions of the pile yarns, hydrophobic stitch loops 340." formalternate stitch loops in each stitch loop chain and hydrophilic stitchloops 34d" form intervening stitch loops therein. By this arrangement,the higher hydrophobic pile loops 33d' define the skin-contactingsurface of the pile face on the pile central panel 35d and will serve towick moisture away fromthe skin of the wearer. The lower hydrophilicpile loops 33d" will absorb the moisture being wicked away from the skinby the hydrophobic pile loops 33d such that the moisture is collectedaway from the skin of the wearer.

In certain instances, it may be desirable to utilize corespun yarns asthe hydrophilic pile yarns 32d" wherein a strong core, such ascontinuous filament, has a sheath of the hydrophilic fibers spuntherearound. Such corespun yarns would provide greater strength andwearability than yarns formed entirely of the hydrophilic fibers, and inaddition, such core-spun yarns would provide a means of controllingshrinkage of the hydrophilic pile yarns upon repeated launderings tobetter maintain the hydrophilic pile loops 33d closer to the height ofthe hydrophobic pile loops 33a.

The above described hydrophobic and hydrophilic high-low pile may beobtained with a diaper material wherein the differential shrinkagecharacteristics of the hydrophobic pile yarns and hydrophilic pile yarnsupon repeated launderings provide pile loops of different height frompile loops which were initially of the same height. In such a diaperconstruction, the hydrophobic pile yarns are preferably used to formalternate rows of pile loops and the hydrophilic pile yarns arepreferably used to form intervening rows of pile loops.

Upon repeated launderings, the hydrophilic pile yarns will swell, openor blossom-out, and shrink so that the hydrophilic pile loops 33c(FIGURES 21 and 22) will become of reduced height and of increased sizeor diameter to more completely fill the spaces between the hydrophobicpile loops 33c. In contrast thereto, the hydrophobic pile loops 33c willnot swell, open or shrink to any appreciable extent. The launderingconditions have some effect upon the hydrophobic pile loops 33c and thiseffect manifests itself in a tendency of the hydrophobic pile loops 33:2to assume irregular shapes and positions with respect to the base 31c.These positions may include a twisting of the pile loops uponthemselves, in a flattening out of the pile loops, and/or in the pileloops becoming tilted over with respect to the base (FIG- URES 21 and22). Even with this effect upon the hydrophobic pile loops, however, thehydrophobic pile loops 332' still remain at a higher elevation than thehydrophilic pile loops 33e" such that the hydrophobic pile loops 33cwill contact the skin of the wearer and wick moisture away from thewearers skin to be absorbed by the hydrophilic pile loops 33:2 disposedaway from the skin of the wearer.

The swelling, shrinkage and opening of the hydrophilic pile yarns uponlaunderings also results in the stitch loops 34e" formed therebybecoming loosened and more open or blossomed-out. This provides asofter, more comfortable surface on this side of the diaper. In contrastto the hydrophilic stitch loops 346", the hydrophobic stitch loops 34aremain rather tight and close to the surface of the base whichcontributes to the pile loops 332' being of a greater height than pileloops 33c".

Alternatively, the above-mentioned hydrophobic and hydrophilic featuresmay be obtained in the pile area of a diaper formed in accordance withthe present invention by the use of a crespun yarn 62 (FIGURE as each ofthe pile yarns. This yarn 62 comprises a sheath 63 of suitablehydrophobic fibers spun around a core 64 of hydrophilic fibers. Whenyarns 62 are utilized as pile yarns in the pile area of a diaper of thisinvention and particularly wherein the pile yarns are disposed on theouter surface thereof, the hydrophobic sheaths 63 will serve to wickmoisture away from the wearers skin into the interior of the yarns wherethis moisture is absorbed by the hydrophilic cores 64. Accordingly, thecomfort of the wearer of such a diaper is materially increased since nowet surface remains in engagement with the skin and diaper rash andother skin maladies are inhibited.

In FIGURES 23 through 28, there are shown three additional modifiedforms of the diapers of the present invention which provide the abovedescribed hydrophobic and hydrophilic characteristics. The first form ofdiaper is shown in FIGURES 23 and 24 and is indicated generally at f.Diaper 30 includes a base 31 which is preferably in the form of a singlelayer of pre-woven fabric and, when in web form, preferably has a widthequal to about two and one-half (2 /2) times the desired width of thefinished diaper. Base 31 consists essentially of hydrophobic materialand preferably both the warp and filling yarns thereof are formed ofhydrophobic fibers.

Pile yarns 32] penetrate through an intermediate area of the base 31 andform pile loops 33 on one surface thereof and stitch loops 34 on theother surface thereof. The pile yarns 32f cooperate with the portion ofthe base 31 through which the same penetrate to define a pile area 35which extends throughout the length of the diaper 30 and is of a widthcorresponding to the desired width of the central portion of thefinished diaper. Pile yarns 32 consist essentially of hydrophilicmaterial and preferably are formed of Water swellable cellulosicmaterial, such as viscose rayon, to provide a high degree of absorbencyin the central portion of the finished diaper.

Base 31 has portions 70 and 71 on opposite sides of the pile area 35 andthese portions are folded about fold lines F and F which are spacedapart a distance corresponding to the desired width of the finisheddiaper 30f, in generally an S-type fold. Portion 70 of the base 31] isfolded over into superposed relation to the surface of pile area 35fhaving stitch loops 33f thereon and portion 71 is folded over intosuperposed relation to the surface of pile area 35 having stitch loops34f thereon. Accordingly, the central portion of the diaper is formed inthree superposed sections with a portion 70a of portion 70 of the basedefining one outer or the upper section, a portion 71a of the portion 71of the base defining the other outer or lower section, and pile area 35defining the inner section. superposed portions 70b, 70c and 71b, 710 ofthe respective portions 70 and 71 on opposite sides of the centralportion define pinning panels 36 37] respectively. The diaper 30 ispreferably secured in the folded condition by spaced lines of stitching72 and 73 which preferably penetrate through the three sections of thecentral portion immediately adjacent opposite sides of the pile area 35The second form of diaper is illustrated in FIGURES 25 and 26 and isgenerally indicated at 30g. Diaper 30g comprises a base 31g which isvery similar in construction and dimensions to base 31 described above.In this respect, base.31g consists essentially of hydrophobic materialand preferably both the warp and filling yarns thereof are formed ofhydrophobic fibers. Pile yarns 32g penetrate through an area of the base31g immediately adjacent one side thereof, when the same is in base webform, and form pile loops 33g on one surface thereof and stitch loopchains 34g on the other surface thereof. As in diaper 30;, the pileyarns 32g consist essentially of hydrophilic material and preferablythese yarns are formed of water swellable cellulosic material, such asviscose rayon, to provide the desired absorbency in the diaper 30g.

The diaper blank from which diaper 30g is formed is folded about twospaced fold lines F and F which are disposed a distance apartcorresponding to the desired width of the finished diaper. With thistype of fold, the pile area 35g is first moved into superposed relationto the central portion 74 of the base, and the other side portion 75 ofthe base is then moved into superposed relation to the pile area 35gwhereby the pile area is disposed between the portions 74 and 75 of thebase. The diaper 30g is secured in folded relation by spaced lines ofstitching 76, 77 which preferably penetrate through the three sectionsof the central portion of the diaper immediately adjacent opposite sidesof the pile area 35g. The portions of the base on opposite sides of thecentral portion are formed of two layers of the base 31g and definepinning panels 36g, 37g, respectively.

Diapers 30 and 30g therefore have central portions which have theopposite outer surfaces thereof formed by portions of the hydrophobicbases while the interior thereof is formed by the pile areas with thehydrophilic pi'le yarns. Accordingly, when these diapers are applied tothe wearer, the hydrophobic portion in contact with the wearers skinwicks moisture therefrom into the interior of the central portion wherethe same is absorbed by the pile yarns.

The third form of these diapers is illustrated in FIG- URES 27 and 28and is generally indicated at 30h. This diaper comprises a base 31hformed similarly to the bases 31] and 31g except that when the same isin web form it has a width only twice the desired width of the finisheddiaper. As with other bases, however, base 31h consists essentially ofhydrophobic material and preferably has both the warp and filling yarnsformed of hydrophobic fibers.

Pile yarns 32h penetrate through an intermediate area of the base withone side edge of the pile area 3511 being spaced from one side edge ofthe base 31h a distance corresponding to the desired width of thepinning portions of the finished diaper. Pile yarns 3211 form pile loops33h on one surface of the area of the base through which the samepenetrate, and stitch loop chains 34h on the other surface thereof.These pile yarns consist essentially of hydrophilic material andpreferably are formed of water swellable celluosic material, such asviscose rayon.

The base 3111 is folded about a medially disposed fold line F to formupper and lower sections extending throughout the diaper and with aportion 80 of the section which is devoid of pile being disposed insuperposed relation to the surface of the pile area 35h having pileloops 33h thereon. Diaper 3012 is secured in folded relation by suitablespaced stitching 81, 82 penetrating through the upper and lower sectionsimmediately adjacent opposite sides of the pile area 3511, and overedgestitching 83 along the side thereof opposite the fold line. The portionsof the diaper between the lines of stitching 81, 82 and the side edgesof the diaper define pinning panels 36h and 37h.

Therefore, diaper 30h has a portion of the hydrophobic base defining onesurface thereof and has the hydrophilic pile disposed interioriy of thecentral portion thereof. Accordingly, when the diaper is applied to awearer, the hydrophobic base portion will contact the wearers skin andwill wick the moisture therefrom into the interior of the diaper wherethe moisture will be absorbed by the hydrophilic pile yarns.

It is therefore believed apparent that a novel pile diaper is providedby the present invention wherein enhanced softness, absorbency and/orwearer comfort are achieved to a greater degree than has heretofore beenachieved in diapers. Additionally, diapers of the present inventionprovide these desired characteristics in the diaper without a relianceupon folding of the diaper to provide a large number of layers in thecentral portion thereof, pads, inserts or special weaves.

In the drawings and specification there has been set forth preferredembodiments of the invention, and although specific terms are employed,they are used in a 1 1 generic and descriptive sense only and not forpurposes of limitation, the scope of the invention being defined in theclaims.

What is claimed is:

1. A diaper adapted to be worn having hydrophilic fibers for the desiredabsorbency therein and being characterized by a pile area disposed in anintermediate portion of the diaper between non-pile areas, said diapercomprising a base of pliable material, and pile yarns penetratingthrough a portion of the base and forming raised pile on one surface ofsaid base portion and being interknit and forming stitch loop chains onthe other surface of said base portion to anchor the pile yarns in thebase, and said pile yarns and base portion defining a pile area disposedin the central portion of the diaper when the diaper is in use.

2. A diaper according to claim 1 wherein said base includes superposedupper and lower sections and said pile yarns penetrate through themedial portion of each of said sections and define raised pile faces onopposite outer surfaces of the diaper for contact with the wearers skin.

3. A diaper according to claim 1 wherein said base includes a pluralityof superposed sections, and said pile yarns penetrate through a portionof one of said sections and form raised pile on one surface thereof,which raised pile is disposed interiorly of the central portion of saiddiaper.

4. A diaper adapted to be worn having hydrophilic,

fibers for the desired absorbency therein and being characterized by apile area disposed in an intermediate portion of the diaper betweennon-pile areas, said diaper comprising a base of pliable material, andpile yarns penetrating through a portion of the base and having portionsthereof formed into pile loops extending above one surface of said baseportion to form raised pile thereon, said pile loops being arranged ingenerally parallel rows on the surface of said base portion, each ofsaid pile loops extending diagonally of said base portion and having legportions penetrating through said base portion at spaced points,adjacent loops in each of said rows having the leg portions at one sidethereof penetrating through said base portion at a common point and theleg portions at the other sides thereof penetrating through said baseportion at spaced apart points whereby said pile loops are arranged in azig-zag pattern in each of said rows with leg portions of the pile loopsin one row and the proximal leg portions of the pile loops in theadjacent row being in alignment in a direction longitudinally of therows to provide substantial coverage of the surface of said baseportion, said pile yarns being interknit and forming stitch loop chainson the other surface of said base portion to anchor the pile yarns inthe base portion, and said pile yarns and base portion defining a pilearea disposed in the central portion of the diaper when the diaper is inuse.

5. A diaper according to claim 4 wherein said base is formed ofpre-woven textile fabric formed of sets of warp and filling yarns, andwherein said pile yarns have lower twist therein than said warp andfilling yarns and provide a soft pile face on said base portion.

6. A diaper according to claim 4 wherein said base is formed of anon-woven fabric.

7. A diaper according to claim 4 wherein said base is formed of apre-knitted fabric.

8. A diaper according to claim 4 wherein said pile yarns consistessentially of cellulosic material and have a yarn size within the rangeof 3/1 to /1 and a twist multiple of no more than 3.5 to provide a soft,highly absorbent pile in the central portion of the diaper when thediaper is in use.

9. A diaper adapted to be worn characterized by an intermediate portionhaving a pile face on one surface thereof, said diaper havinghydrophilic fibers therein for the desired absorbency and comprising abase of at least one layer of textile fabric, and pile yarns penetratingthrough an elongate intermediate portion of the base and having portionsthereof extending above and substantially covering one surface of saidintermediate base portion to form a raised pile face thereon, said pileyarns being interknit and forming stitch loop chains on the othersurface of said intermediate base portion to anchor the pile yarnstherein, said intermediate base portion extending throughout onedimension of said diaper and having a width of about one-half the otherdimension of said diaper and being disposed in the central portion ofthe diaper when the diaper is in use with the pile face thereon beingadapted to be in contact with a wearers skin, said base including sideportions on opposite sides of said intermediate portion and definingpinning panels in the diaper for pinning the diaper on a wearer.

.10. A diaper according to claim 9 wherein said base is formed of aplurality of layers of textile fabric and said pile yarns penetratethrough all of the layers of the base and secure these layers togetherin the intermediate portion of the diaper with the layers of the base insaid side portions thereof being independent to facilitate the insertionof pins therethrough for ease in pinning the diaper upon a wearer.

11. A diaper adapted to be worn characterized by an intermediate portionhaving a pile face on at least one surface thereof between nonpileareas, said diaper comprising a base of textile fabric, and low twist,shrinkable pile yarns consisting essentially of cellulosic fibers havinga tendency to mat under laundering conditions and penetrating through anintermediate port-ion of the base and having portions thereof extendingabove and substantially covering one surface of the intermediate baseportion to form a raised pile face thereon, said pile yarns beinginterknit and forming stitch loop chains on the other surface of thebase to anchor the pile yarns in the base, the shrinkability and twistof said pile yarns effecting rearrangement of the pile face into aclosely matted surface upon repeated l aunderings to provide morecomplete coverage of said intermediate base portion, and theintermediate base portion having the pile face thereon being disposed inthe central portion of the diaper when the diaper is in use.

12. A diaper adapted to be worn characterized by an intermediate portionhaving a pile face on at least one surface thereof, said diapercomprising a base of pliable material, and pile yarns penetratingthrough an intermediate portion of the base and having portions thereofextending above one surface thereof to form a raised pile face thereon,said pile yarns being interknit and forming stitch loop chains on theother surface of said intermediate base portion to anchor the pile yarnstherein, certain portions of said pile face being formed ofhydro'pho'bic material and other portions thereof being formed ofhydrophilic material, said hydrophobic portions being arranged to defineat least the outermost surface of said pile face adapted to contact theskin of a wearer and to wick moisture away from the wearers skin, saidhydrophilic portions being arranged relative to said hydrophobicportions to absorb the moisture being wicked away from the skin of awearer by said hydrophobic portions, and the intermediate base port-ionhaving said pile face thereon being disposed in the central portion ofthe diaper when the diaper is in use with the pile face being adapted tobe in contact with the wearers skin.

13. A diaper according to claim 12 wherein said hydrophobic portions ofsaid pile face are defined by pile of a predetermined height and saidhydrophilic portions are defined by pile of a lesser height than saidhydrophobic pile.

14. A diaper according to claim 12 wherein said pile yarns comprisecore-spun yarns each having a hydrophilic core and a hydrophobic sheathof fibers around said hydrophilic core, said hydrophobic sheaths of saidpile yarns defining said hydrophobic portions of said pile face and saidhydrophilic cores of said pile yarns defining said hydrophilic portionsof said pile face so that moisture is Wicked to the interior of saidpile yarns by said hydrophobic sheaths and is absorbed by saidhydrophilic cores away from the wearers skin.

15. A diaper adapted to be worn characterized by an intermediate portionhaving a pile face on at least one surface thereof, said diapercomprising a base of pliable material, and pile yarns penetratingthrough an intermediate portion of the base and having portions thereofformed into pile lo'ops extending above one surface of said intermediatebase portion to form a raised pile face thereon, said pile loops beingof different heights with the higher pile loops being formed from pileyarns of hydrophobic material and the lower pile loops being formed ofhydrophilic material and being interspersed with said hydrophobic pileloops over substantial areas of the pile face, said pile yarns beinginterknit and forming stitch loop chains on the other surface of saidintermediate base portion to anchor the pile yarns therein, and saidintermediate base portion having the pile face thereon being disposed inthe central portion of the diaper when the diaper is in use With thepile face being adapted to be in contact with the skin of a wearer sothat moisture will be wicked away from the Wearers skin by said higherhydrophobic pile loops and absorbed away from the wearers skin by saidlower hydrophilic pile loops.

16. A diaper according to claim 15 wherein said pile loops are arrange-din generally parallel rows on the surface of said intermediate baseportion, with said hydrophobic pile loops defining certain rows, andsaid hydrophilic pile loops defining certain other rows interspersedtherewith.

'17. A diaper adapted to be worn characterized by an intermediateportion having a pile face on at least one surface thereof, said diapercomprising a base of pliable material, and pile yarns penetratingthrough an intermediate portion of the base and having portions thereofextending above one surface thereof to a common height to form a raisedpile face thereon, certain of said pile yarns being formed ofhydrophobic material and the remainder of said pile yarns being formedof hydrophilic material, said hydrophilic pile yarns having a low twistand being contractible upon repeated launderings to effect a reductionof the pile formed by said hydrophobic pile yarns, said pile yarns beinginterknit and forming stitch loop chains on the other surface of saidintermediate base portion to anchor the pile yarns therein, and saidinter-mediate base port-ion having the pile face thereon being disposedin the central portion of the diaper when the diaper is in use with thepile face being adapted to be in contact with the wearers skin.

'18. A diaper adapted to be worn characterized by an intermediate pileportion disposed in the central portion of the diaper when the diaper isin use, said diaper comprising a base of textile fabric and pile yarnspenetrating through a portion of the base and forming raised pile on onesurface of said base portion and being interknit and forming stitch loopchains on the other surface of said base portion to anchor the pileyarns therein, the remaining portions of said base being devoid of pile,said pile yarns being formed of hydrophilic fibers for absorbency, saidbase being arranged in a plurality of superposed sections with said baseportion penetrated by said pile yarns being disposed in the centralportion of the diaper and with a section of said base devoid of pilebeing disposed in superposed contiguous relation to the raised pile onone surface of said base portion to position said pile interiorly of thecentral portion of the diaper, and at least said section of the base insuperposed contiguous relation to said pile portion being formed ofhydrophobic material and being adapted to contact the Wearers skin towick moisture therefrom into the interior of the diaper for absorptionby said hydrophilic pile.

19. A diaper according to claim 18 wherein said base is arranged inthree superposed sections in the central portion of the diaper with saidpile portion defining the internal section between opposite outersect-ions devoid of .pile which define opposite outer surfaces of thecentral portion of the diaper, and wherein at least said outer sectionsof said base are formed of hydrophobic material.

References Cited UNITED STATES PATENTS 2,331,289 10/1943 Amid on 66-852,890,5 79 6/1959 Mauersberger 6685 3,113,570 l 2/ l963 Holliday et al.128284 3,224,446 12/ 1965 Gore 128-2-84 3,25 3,426 5/ 1966 Mauersberger6685 FOREIGN PATENTS 10,928 1897 Great Britain.

RICHARD A. GAUDET, Primary Examiner.

CHARLES F. ROSENBAUM, Examiner.

1. A DIAPER ADAPTED TO BE WORN HAVING HYDROPHILIC FIBERS FOR THE DESIREDABSORBENCY THEREIN AND BEING CHARACTERIZED BY A PILE AREA DISPOSED IN ANINTERMEDIATE PORTION OF THE DIAPER BETWEEN NON-PILE AREAS, SAID DIAPERCOMPRISING A BASE OF PLIABLE MATERIAL, AND PILE YARNS PENETRATINGTHROUGH A PORTION OF THE BASE AND FORMING RAISED PILE ON ONE SURFACE OFSAID BASE PORTION AND BEING INTERKNIT AND FORMING STITCH LOOP CHAINS ONTHE OTHER SURFACE OF SAID BASE PORTION TO ANCHOR THE PILE YARNS IN THEBASE, AND SAID PILE YARNS AND BASE PORTION DEFINING A PILE AREA DISPOSEDIN THE CENTRAL PORTION OF THE DIAPER WHEN THE DIAPER IS IN USE.